1989 FORD FIESTA height

clamp brackets and disconnect the pipe joint
union over the top of the cylinder head cover.
Place absorbent rags beneath the union as it
is disconnected to soak up escaping fluid and
plug the open unions to prevent dirt entry and
further fluid loss. Move the pipe(s) clear just
sufficiently to allow removal of the cylinder
head cover.
5Remove the timing belt upper cover (see
Section 7).
6 Disconnect the crankcase breather hose
from the cylinder head cover union (see
illustration) .
7 Unplug the HT leads from the spark plugs
and withdraw them, unclipping the leads from
the cover.
8 Working progressively, unscrew the
cylinder head cover retaining bolts, noting the
spacer sleeve and rubber seal at each, then
withdraw the cover (see illustration).
9 Discard the cover gasket; this mustbe
renewed whenever it is disturbed. Check that
the sealing faces are undamaged, and that the
rubber seal at each retaining bolt is
serviceable; renew any worn or damaged
seals.
Refitting
10 On refitting, clean the cover and cylinder
head gasket faces carefully, then fit a new
gasket to the cover, ensuring that it locates
correctly in the cover grooves (see illustration).
11 Refit the cover to the cylinder head, then
insert the rubber seal and spacer sleeve at
each bolt location (see illustration). Start allbolts finger-tight, ensuring that the gasket
remains seated in its groove.
12
Working in a diagonal sequence from the
centre outwards, and in two stages (see
Specifications), tighten the cover bolts to the
specified torque wrench setting.
13 Refit the HT leads, clipping them into
place so that they are correctly routed; each is
numbered, and can also be identified by the
numbering on its respective coil terminal.
14 Reconnect the crankcase breather hose,
and refit the timing belt upper cover.
Reconnect and adjust the accelerator cable,
then refit the air inlet components (see
Chapter 4B).
15 On models with power steering,
reconnect the high pressure fluid pipe then
bleed the system as described in Chapter 10.
5 Valve clearances -
general information
Refer to Section 5 in Part B of this Chapter.
6 Crankshaft pulley -
removal and refitting
1
Removal
1 Remove the auxiliary drivebelt - either
remove the drivebelt completely, or just secure it clear of the crankshaft pulley,
depending on the work to be carried out (see
Chapter 1).
2
If necessary, rotate the crankshaft until the
timing marks align (see Section 3).
3 The crankshaft must now be locked to
prevent its rotation while the pulley bolt is
unscrewed. To do this, remove the starter
motor (Chapter 5A) and lock the starter ring
gear teeth using a suitable screwdriver.
4 It should now just be possible to reach
between the crankshaft pulley and the body
side member to undo and remove the pulley
bolt and withdraw the pulley. However, if
additional working clearance is needed,
proceed as follows.
5 If not already done, chock the rear wheels
then jack up the front of the car and support it
on axle stands (see “Jacking and Vehicle
Support” ). Remove the front right-hand
roadwheel.
6 Support the weight of the
engine/transmission using a trolley jack, with
a wooden spacer to prevent damage to the
sump.
7 From above, unscrew the three bolts
securing the engine’s front right-hand (Y-
shaped) mounting bracket to the alternator
mounting bracket. Unfasten the engine’s rear
right-hand mounting from the body by
unscrewing first the single nut (and washer)
immediately to the rear of the timing belt
cover, then the bolt in the wheel arch
8 With the engine’s right-hand mountings
unfastened from the body, lower the
engine/transmission on the jack until a socket
spanner can be fitted to the crankshaft pulley
bolt.
9 With the starter ring gear teeth locked,
unscrew the crankshaft pulley bolt and
withdraw the pulley (see illustration).
Refitting
10Refitting is the reverse of the removal
procedure; ensure that the pulley’s keyway is
aligned with the crankshaft’s locating key, and
tighten the pulley bolt to the specified torque
wrench setting. If the engine mountings were
disturbed, use the jack to adjust the height of
the engine/transmission until the bolts (and
nut, with washer) can be refitted and screwed
2C•4 Zetec engine in-car repair procedures
6.9 Unscrew pulley bolt to release
crankshaft pulley4.11 Ensure rubber seal is fitted to eachcover bolt spacer, as shown
4.10 Ensure gasket is located correctly in cover groove4.8 Removing cylinder head cover
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Fuel pump
Delivery pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 0.24 to 0.38 bars
Carburettor data
Weber (1V) TLM carburettor - 1.0 litre HCS engines
Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1Fast-idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 3400 ± 100 rpm
Float height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 26.0 ± 1.0 mm
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 23 mm
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . 110
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 220
Weber (2V) TLDM carburettor - 1.1 litre HCS engines
Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1Fast-idle speed:
Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 2800 rpm
CTX automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2600 rpm
Float height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 29.0 ± 1.0 mm
Throttle kicker speed: Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1250 to 1350 rpm
CTX automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050 to 1150 rpm
PrimarySecondary
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 26 mm 28 mm
Main jet: Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 92122
CTX automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92112
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . F113 F75
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 195 155
Weber (2V) TLDM carburettor - 1.3 litre HCS engines
Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Fast-idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 2500 rpmFloat height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 29.0 ± 1.0 mm
Throttle kicker speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 1900 ± 100 rpm
PrimarySecondary
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 19 mm 20 mm
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . 90122
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . F113 F75
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 185 130
Weber (2V) DFTM carburettor - 1.4 litre CVH engines
Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Fast-idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 2800 ± 100 rpm
Choke pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 2.7 to 3.2 mm
Float height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 8.0 ± 0.5 mm
Throttle kicker speed:
Manual transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1300 ± 50 rpm
CTX automatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100 ± 50 rpm (in Neutral)
PrimarySecondary
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 21 mm 23 mm
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . 100 125
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 210 155
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . F22 F60
Idle jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . . 4260
Weber (2V) TLD carburettor - 1.6 litre CVH engines
Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1 Fast-idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . 1800 ± 50 rpm (on third step of fast-idle cam)
Choke pull-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 4.7 ± 0.5 mm
Float height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . 29.0 ± 0.5 mm
PrimarySecondary
Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 2123
Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . . . 117 127
Emulsion tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . F105 F71
Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . 185 125
Torque wrench settingsNmlbf ft
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . . . . 16 to 20 12 to 15
Inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . . . . 16 to 20 12 to 15
4A•2 Fuel system – carburettor engines
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10
1595Ford Fiesta Remake
Wheel alignment and steering angles
Front wheel toe setting:Pre-1990 models: Tolerance allowed before resetting required . . . . . . . . . . . . . . . . . 3.0 mm toe-out to 3.0 mm toe-in (0°30’ toe-out to 0°30’ toe-in)
Adjustment setting (if required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel ± 1.0 mm (0° ± 0°10’)
1990 models onward: All models except Turbo:
Tolerance allowed before resetting required . . . . . . . . . . . . . . \
. . 4.5 mm toe-out to 0.5 mm toe-in (0°45’ toe-out to 0°05’ toe-in)
Adjustment setting (if required) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm toe-out ± 1.0 mm (0°20’ toe-out ± 0°10’)
Turbo models:
Tolerance allowed before resetting required . . . . . . . . . . . . . . \
. . 4.0 mm toe-out to parallel (0°40’ toe-out to 0°0’)
Adjustment setting (if required) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm toe-out ± 1.0 mm (0°20’ toe-out ± 0°10’)
Chapter 10
Suspension and steering
Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . .See Chapter 1
Front hub bearings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front spindle carrier - removal and refitting . . . . . . . . . . . . . . . . . . . 2
Front suspension anti-roll bar - removal and refitting . . . . . . . . . . . . 6
Front suspension crossmember - removal and refitting . . . . . . . . . . 7
Front suspension lower arm - removal and refitting . . . . . . . . . . . . . 8
Front suspension strut - dismantling, examination and reassembly . . 5
Front suspension strut - removal and refitting . . . . . . . . . . . . . . . . . 4
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . 1
Power steering fluid cooler - removal and refitting . . . . . . . . . . . . . . 26
Power steering fluid level check . . . . . . . . . . . . .See
“Weekly Checks”
Power steering hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . 27
Power steering pump - removal and refitting . . . . . . . . . . . . . . . . . . 25
Rear axle (all models except Courier) - removal and refitting . . . . . . 12
Rear axle pivot bushes (all models except Courier) - renewal . . . . . 13
Rear hub bearings - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Rear shock absorber (Courier models) - removal, examination and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . . . . 16 Rear strut (all models except Courier) - dismantling, examination
and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .\
. . . 11
Rear strut (all models except Courier) - removal and refitting . . . . . 10
Rear suspension anti-roll bar (all models except Courier) - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Rear suspension assembly (Courier models) - removal and refitting . . 17
Rear suspension components (Courier models) - general . . . . . . . . 15
Rear suspension ride height (Courier models) - adjustment . . . . . . . 18
Steering column (manual steering) - removal and refitting . . . . . . . . 20
Steering column (power steering) - removal and refitting . . . . . . . . . 21
Steering gear (manual steering) - removal and refitting . . . . . . . . . . 23
Steering gear (power steering) - removal and refitting . . . . . . . . . . . 24
Steering gear rubber gaiters - renewal . . . . . . . . . . . . . . . . . . . . . . . 22
Steering wheel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 19
Suspension and steering check . . . . . . . . . . . . . . . . . . .See Chapter 1
Track rod end balljoint - removal and refitting . . . . . . . . . . . . . . . . . 28
Tyre condition and pressure checks . . . . . . . . . .See “Weekly Checks”
Wheel alignment and steering angles - general information . . . . . . . 29
10•1
Specifications Contents
Easy, suitable for
novice with little
experience Fairly easy,
suitable
for beginner with
some experience Fairly difficult,
suitable for competent
DIY mechanic
Difficult,
suitable for
experienced DIY
mechanic Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
54321
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positioning of the voids. Install the bush on
the other side in the same way.
9With the new bushes in position, refit the
body mounting brackets loosely to the trailing
arms - do not fully tighten the pivot bolts at
this stage. Final tightening is carried out with
the vehicle standing on its roadwheels.
10 Raise the axle assembly so that the
conical locating pegs on the body mounting
brackets engage in their body locations. Refit
the body mounting bracket bolts and tighten
to the specified torque.
11 On ABS equipped models, reconnect the
load-apportioning valve operating links to the
rear axle beam
12 If the flexible brake hoses were
disconnected during this operation, reconnect
them and bleed the brake hydraulic system
(see Chapter 9).
13 Lower the vehicle to the ground.
14 Fully tighten the bush pivot bolt nuts to
the specified torque.
April 1990 models onward
15 As mentioned in the note at the start of
this Section, all later models are fitted with
revised bushes which use 12 mm (thread size)
pivot bolts. If the later type bushes are to be
fitted to a pre-April 1990 model, two
corresponding bolts and nuts must be
obtained at the same time, and either the
body mounting brackets must be replaced by
the corresponding modified items, or the
holes in the original brackets must be opened
out (to 12.5 mm) to suit the new bolts.
16 Carry out the operations described in
paragraphs 1 to 4 above.
17 Using a steel tube of suitable diameter,
various flat washers and a long bolt and nut,
draw the bush out of its location in the axle
trailing arm.
18 Clean the bush eye in the trailing arm;
lubricate it, and the new bush, with a soapy
solution (washing-up liquid, for example) prior
to installation.
19 Locate the new bush in position, together
with the steel tube, washers, bolt and nut as
used for removal. Ensure that the bush flange
is positioned on the outside, then draw the
bush fully into position so that its lip is
engaged (see illustration) .
20 Raise the axle to reposition the bush pin bores in line with the bolt holes in the
mounting brackets, then insert the pivot bolts.
Screw the retaining nuts into position on the
pivot bolts, but do not fully tighten them at
this stage.
21
Carry out the operations described in
paragraphs 11 to 14 above.
14 Rear suspension anti-roll bar (all models except Courier) -
removal and refitting
2
Removal
1 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and Vehicle Support” ).
2 Undo the front clamp bolt from each end of
the bar, then support the bar and undo the
rear bolt at each end; withdraw the bar (see
illustration) .
3 Prise open the clamps to release the rubber
bushes, if required. Fit the new bushes using
soapy water as a lubricant.
Refitting
4 On refitting, offer up the bar and align first
the front clamp on each side, refitting the
bolts loosely.
5 Align and refit the rear clamp on each side;
again, tighten the bolts only loosely. 6
Lower the vehicle to the ground, rock it to
settle the suspension, then tighten the clamp
bolts to the specified torque settings.
15 Rear suspension components (Courier
models) - general
Although it is possible to remove the rear
suspension torsion bars and stabiliser bar
independently of the complete rear axle
assembly, it is essential to have certain
special tools available to complete the work
successfully.
Due to the complexity of the tasks, and the
requirement for special tools to accurately set
the suspension geometry and vehicle ride
height on refitting, the removal and refitting of
individual rear suspension components is
considered to be beyond the scope of DIY
work and should be entrusted to a Ford
dealer. Procedures for removal and refitting of the
rear shock absorbers, and the complete rear
suspension assembly are given in Sections 16
and 17 respectively.
16 Rear shock absorber (Courier models) - removal,
examination and refitting
1
Removal
1 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and Vehicle Support” ).
2 Support the relevant trailing arm of the
suspension assembly and unscrew the upper
mounting bolt and nut, followed by the lower
bolt. Withdraw the shock absorber from under
the vehicle (see illustrations) .
Examination
3Examine the shock absorber body for signs
of fluid leakage or damage and check the
Suspension and steering 10•11
14.2 Rear suspension anti-roll bar
1 Rear suspension strut
2 Anti-roll bar
3 Inset showing (front) mounting clamp13.19 Pivot bush renewal (April 1990
models onwards) - correct engagement of bush lip on rear axle
A New bush, installed correctly
B New bush, installed incorrectly
16.2b . . . and lower mounting on Courier models16.2a Removing a shock absorber uppermounting . . .
10
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mountings for signs of wear. Test the
operation of the unit, holding it in an upright
position, by moving the piston through a full
stroke, and then through short strokes of 50
to 100 mm. In both cases, the resistance felt
should be smooth and continuous. If the
resistance is jerky, or uneven, or if there is any
visible sign of wear or damage, the shock
absorber should be renewed. Note that if
either unit is to be renewed, it is good practice
to renew both together as a matched pair.
Refitting
4Locate the unit in position and refit the
mounting bolts and nut. Do not fully tighten
the mountings at this stage.
5 Lower the vehicle to the ground and rock it
to settle the suspension. Raise the vehicle
again, as necessary, until the shock absorber
is at an angle of 50° ± 5° to the horizontal.
With the shock absorber in this position,
tighten the upper and lower mountings to the
specified torque.
17 Rear suspension assembly (Courier models) -
removal and refitting
3
Removal
1 Chock the front wheels then jack up the
rear of the car and support it on axle stands
(see “Jacking and Vehicle Support” ). Remove
the rear roadwheels.
2 Refer to Chapter 9 for details, and
disconnect the handbrake cable equaliser
from the primary cable. Remove the
handbrake rear cable from its adjuster and its
fixed body locations. Release the exhaust
system mountings as necessary to allow the
handbrake cable to be withdrawn over the
rear of the exhaust.
3 Disconnect the rear brake flexible hydraulic
brake hoses from their rigid line connections
(see illustration) . Clamp the hoses before
disconnecting them, to minimise the fluid loss
and air entry into the hydraulic system (see
Chapter 9 for details).
4 Detach the light-laden valve linkage from
the bracket on the suspension assembly. 5
Locate suitable jacks under the suspension
assembly to support its weight (not to lift it).
6 Unscrew the shock absorber lower
mounting bolts on each side.
7 Unscrew the two mounting bracket bolts
each side (see illustration) , check that all
associated fittings are clear, then lower the
suspension assembly and remove it from
under the vehicle.
Refitting
8 Refitting is a reversal of the removal
procedure, but note the following: a) Refit the front mounting brackets first,
and tighten the retaining bolts to the
specified torque.
b) Reconnect the shock absorber lower
mountings, but do not fully retighten the
securing bolts until after the vehicle is
lowered to the ground and is standing on
its wheels.
c) Ensure that all brake fluid line connections are clean before reconnecting them. Refer
to the appropriate Sections in Chapter 9
for specific details on reconnecting the
brake lines, bleeding the brake hydraulic
system, adjusting the light laden valve,
and reconnecting and adjusting the
handbrake cable.
d) Once the vehicle is standing on its
wheels, raise it again, as necessary, until
the shock absorbers are at an angle of
50° ± 5° to the horizontal. With the shock
absorbers in this position, tighten the
lower mountings to the specified torque.
18 Rear suspension ride height (Courier models) - adjustment
4
Checking of the ride height requires the use
of Ford special tools to accurately compress
the suspension to a pre-determined value.
Further special tools are then required to
reposition the torsion bars to the new setting.
This operation should be entrusted to a
Ford dealer, as it is not possible to carry out
the procedure accurately without the use
of the appropriate tools.
19 Steering wheel -
removal and refitting
2
Removal
Models without air bag
1 Drive the vehicle in a straight line onto a
level surface, so that the roadwheels are
pointing straight ahead.
2 Carefully prise the motif from the centre of
the steering wheel (see illustration).
3 Mark the relative positions of the steering
wheel and steering column shaft.
4 Unscrew the retaining bolt from the centre
of the steering wheel, then insert the ignition
key and turn it to position “I”. Grip the wheel
each side, then pull and withdraw it from the
column shaft.
Models with air bag
Warning: Handle the air bag with
extreme care as a precaution
against personal injury, and
always hold it with the cover
facing away from your body. If in doubt
concerning any proposed work involving
the air bag or its control circuitry, consult a
Ford dealer or other qualified specialist.
5 Disconnect the battery negative (earth) lead
(refer to Chapter 5A, Section 1).
Warning: Before proceeding,
wait a minimum of 15 minutes,
as a precaution against
accidental firing of the air bag.
This period ensures that any stored energy
in the back-up capacitor is dissipated.
6 Undo the screws, and remove the steering
column lower shroud.
7 Undo the two external screws and the two
internal screws and remove the steering
column upper shroud.
10•12 Suspension and steering
19.2 Removing the motif from the steering wheel17.7 Courier rear suspension pivot
brackets locate on dowels in underbody17.3 Brake hose and rigid pipe connection on Courier rear suspension assembly
1595Ford Fiesta Remake
If the wheel is tight, tap it up
near the centre, using the
palm of your hand, or twist it
from side to side, whilst
pulling upwards to release it from the
shaft splines.
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4Pull the latch end of the cable into the
engine compartment, noting cable routing and
clips fitted. Remove the cable from its clips.
5 Detach the cable from its release lever on
the steering column, by aligning the cable
core with the slot on the release lever and
withdrawing the end fixing. Detach the cable
from its outer core abutment on the steering
column lock housing.
6 Unclip the cable from its pedal box
location, then detach the bulkhead grommet
and pass the cable through into the engine
compartment. Withdraw the cable from the
vehicle.
7 The release lever on the steering column
may be removed, if required, by unhooking
the spring from its retaining arms, then
disengaging its retaining arms from the
steering column lock housing.
Refitting
8 Refit the release lever, if removed, by
reversing the method of removal.
9 To install the release cable, first pass the
latch end of the cable down the right-hand
side of the steering column, through its
bulkhead location, and out into the engine
compartment.
10 Fit the cable to its clip on the pedal box
assembly, then reconnect the cable to the
release lever and the steering column lock
housing abutment by reversing the method of
removal.
11 Where applicable, refit the choke warning
light switch/pull control assembly, to the lower steering column shroud, by reversing the
method of removal. Refit the shroud.
12
Seat the release cable grommet into the
bulkhead.
13 Route and secure the release cable in the
engine compartment.
14 Reconnect the release cable to the latch,
then refit the latch to the body, setting the
latch at its maximum height position, and
tightening only the bottom retaining screw.
15 Adjust the latch for flush bonnet closure in
accordance with Section 8.
8 Bonnet latch - adjustment
1
1To adjust the bonnet latch, remove the two
upper latch retaining screws, then with the
latch raised to its maximum height position
and secured with the lower retaining screw,
close the bonnet.
2 Slacken the lower latch retaining screw,
through the gap between the leading edge of
the bonnet and the radiator grille slot, then
set the bonnet so it sits flush with its
surrounding panels - it may be necessary to
adjust the height of the bump stops (see
Section 6) if they have been moved in any
way, or if fitting a new bonnet.
3 With the desired bonnet closure obtained,
fully tighten the lower latch retaining screw,
then open the bonnet and refit the two upper
latch retaining screws, tightening to the
specified torque.
9 Body adhesive emblems -
renewal
1
1 Using a length of strong thin diameter cord
(fishing line is ideal), break the adhesive bond
between the emblem and the panel.
2 Thoroughly clean all traces of the old
adhesive from the emblem location, using
methylated spirit, taking all normal safety
precautions. Allow the emblem location to
dry.
3 Gently heat the new emblem until it is warm
to the touch. 4
Peel the protective backing paper from the
emblem then, taking care not to touch the
adhesive, position the emblem on the panel.
Maintain hand pressure evenly for at least
thirty seconds to ensure a good bond.
10 Body trim mouldings -
removal and refitting
1
Roof drip rail moulding (all
models except Courier)
Removal
1 Remove the drip rail moulding by gently
raising the forward end from its retaining
flange, taking care not to bend or kink it, then
carefully pull it off the retaining flange (see
illustration) .
Refitting
2To refit the drip rail moulding, first align the
rear of the moulding to the roof panel edge by
the tailgate, then, using the flat palm of the
hand, gently tap the moulding down.
3 If fitting the Ford roof rack, the drip rail
mouldings on both sides must be removed
and replaced by a ten-piece moulding kit,
available from Ford dealerships.
Roof drip rail moulding (Courier
models)
Removal
4 These are released by lifting and gripping
the moulding’s inboard edge, then by
rotating the whole length of the moulding
towards the outside of the vehicle to release it
from its outboard lip.
Refitting
5 Refitting is the reverse of the removal
procedure; ensure that the moulding’s
outboard edge is seated securely in its lip
before pressing the inboard edge firmly into
place.
Door side moulding
Removal
6 Apply masking tape, as an alignment guide
and to protect the paintwork, just above and
just below the moulding to be renewed.
7 Using a length of strong thin diameter cord
(fishing line is ideal), break the bond between
the moulding and the panel, and remove the
moulding (see illustration) .
Refitting
8Thoroughly clean the moulding location of
any trace of old adhesive, using methylated
spirit, taking all normal safety precautions.
Allow the moulding location to dry.
9 Continue to proceed using a similar
technique to that described in Section 9
taking care to align the moulding correctly.
10 To improve the adhesive bond, apply
pressure over the whole length of the
moulding using a roller.
11 Remove the masking tape carefully.
Bodywork and fittings 11•5
7.3b Bonnet release cable attachments at
the latch
A Outer cable attachment
B Inner cable attachment
10.7 Removing a door side moulding
A Masking tape C Nylon cord (fishing line)
B Moulding
10.1 Removing a roof drip rail moulding
11
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3Remove the B-pillar trim and sill scuff plate
as described in Section 42.
4 Remove the bolt (two bolts on later models)
securing the seat belt retractor unit to its
location in the base of the B-pillar (see
illustration) , then remove the retractor unit
and the seat belt from the vehicle.
Front seat belt (three-door models)
5 Remove the rear quarter trim panel, as
described in Section 42.
6 Undo the bolt securing the seat belt
retractor unit to its location, then remove the
retractor unit and seat belt from the vehicle.
Front seat belt (Van models)
7 Remove the cover from the upper anchor
position and remove the anchor bolt.
8 Undo the bolt securing the retractor unit
and integral lower anchor position, then
remove the retractor unit and seat belt from
the vehicle.
Front seat belt stalk
Warning: On vehicles fitted with
mechanical seat belt pre-
tensioners, any work on the seat
belt stalk should be entrusted to
a Ford dealer. The following procedure is
therefore only applicable to models with conventional seat belt stalks which DO
NOT incorporate any form of pre-
tensioning device.
9
Remove the bolt securing the seat belt stalk
assembly to the floor, between the two front
seats, noting the arrangement of washers and
spacers (see illustration) . Remove the stalk
assembly from the vehicle.
Front seat belt height adjuster
Note : If a height adjuster mechanism is not
fitted, it is possible to lower the upper anchor
position from its production setting, by
removing the plug from the lower adjuster
plate hole and bolting the anchor into this (see
illustration 41.13) . The plug can then be fitted
to the production setting hole.
10 Remove the height adjuster knob by
carefully inserting a small screwdriver into the
aperture on the underside of the knob, and
gently levering it off.
11 Remove the anchor cover, again using a
screwdriver, then remove the anchor bolt and
anchor (see illustration) .
12 Remove the door aperture weatherseal(s)
around the B-pillar location, then remove the
B-pillar trim, as described in Section 42.
13 Remove the bolts securing the adjuster
plate to the B-pillar, noting washer fitment, then remove the adjuster plate from the
vehicle
(see illustration) .
Rear seat belts
14Remove the rear seat cushion, as
described in Section 40, then also remove the
parcel shelf.
15 Undo the bolt securing each seat belt
buckle assembly to its body location (see
illustration) , and remove the buckle
assemblies from the vehicle, as required.
16 Prevent the retractor units from reeling in
too much seat belt by attaching a clothes peg
or similar item to the belt, close to the
retractor unit.
17 Detach the seat belt lower anchor by
removing its retaining bolt.
18 Remove the upper anchor bolt cover and
undo the bolt securing the anchor to its
location. Detach the anchor, noting any
spacer fitment.
19 On vehicles fitted with a parcel shelf,
remove the seat belt guide from the parcel
shelf support/rear loudspeaker housing, then
pass the seat belt through it.
20 On vehicles without a parcel shelf as
standard, remove the trim panel covering the
seat belt retractor unit, where fitted, by
undoing its retaining screws. Remove the seat
belt guide from the trim panel, then pass the
seat belt through it.
21 Remove the bolt securing the seat belt
retractor unit to its body location, then
withdraw the retractor unit and the seat belt
from the vehicle.
Refitting
22 Refitting is a reversal of the removal
procedure, noting the following points. Ensure
that the tag on the retractor unit engages in its
body location and, in the case of the rear seat
belts, that it does not trap the wiring loom
between itself and the body. Having fitted the
upper anchor to its location, ensure that it can
rotate freely. The stalk assembly anchor(s)
must engage to the anti-rotation floorpin(s)
and, when refitting a rear centre lap
belt/buckle assembly, the lap belt must be
fitted to lie on the right-hand side of the
vehicle. Tighten all bolts to their specified
torque.
11•18 Bodywork and fittings
41.15 Rear seat belt and buckle securing
arrangements (rear seat cushion removed)
A Seat belt lower anchor retaining bolts
B Centre lap belt/single buckle assembly securing bolt
C Dual buckle assembly securing bolt41.13 Seat belt upper anchor position (fixed and adjustable)
A Adjuster plate securing bolt
B Anchor bolt position (production setting)
C Lower setting for fixed type (if required)
41.11 Removing a seat belt upper anchor cover41.9 Front seat belt stalk assembly
A Bolt
B Anti-rotation plate
C Stalk D Metal washers
E Paper washer
F Floorpin
41.4 Seat belt retractor unit location in
base of B-pillar (five-door models)
A Retractor unit locating tag
B Retractor unit securing bolt
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42 Interior trim panels-
removal and refitting
2
A-pillar trim
Removal
1 Remove the securing screw from the trim
panel, located near to the windscreen top
corner (see illustration) .
2 Detach the door aperture weatherseal from
around the trim panel, then pull the trim panel
from the pillar.
Refitting
3 To refit, align the trim fixing lugs to the pillar
and press into position. Refit the securing
screw then push the door aperture
weatherseal back onto its flange.
B-pillar trim
Removal
4 Remove the front seat belt height adjuster
knob, as applicable, by inserting a small
screwdriver into the aperture on the underside
of the knob and levering it off.
5 Remove the upper seat belt anchor bolt
cover, and remove the bolt, as required.
6 Open the doors and detach the door
aperture weatherstrip from the area around
the B-pillar trim. 7
Remove the securing screws and detach
the trim.
Refitting
8 Refitting is the reverse sequence to
removal, tightening the seat belt anchor bolt
to the specified torque. Ensure that the
anchor is free to rotate.
C-pillar trim
Removal
9 Open the tailgate, then detach the
loudspeaker from its location by
disconnecting its multi-plug connection,
removing its two retaining screws and
unhinging it.
10 Detach the tailgate weatherstrip from its
flange, around the trim panel.
11 Remove the parcel shelf, then slacken the
parcel shelf support/rear loudspeaker housing
retaining screws, and remove the single screw
from the base of the C-pillar trim (see
illustration) .
12 Remove the upper seat belt anchor bolt
cover, and remove the bolt and anchor, noting
any spacer fitment.
13 Remove the screw(s) from the top of the
C-pillar trim, then remove the trim from the
vehicle.
Refitting
14 To refit, position the base of the trim behind the parcel shelf support/rear
loudspeaker housing, then loosely refit the
upper and lower securing screws.
15
Refit the seat belt anchor, bolt, and
spacer, as applicable, tightening the bolt to
the specified torque. Refit the anchor bolt
cover, and ensure that the anchor is free to
rotate.
16 Tighten the trim and parcel shelf
support/rear loudspeaker housing screws,
then refit the parcel shelf.
17 Refit the loudspeaker by reversing the
method of removal, then press the tailgate
weatherstrip back into place.
Sill scuff plate
Removal
18 Remove the front seat adjacent to the
scuff plate to be removed (see Section 39).
19 Detach the door aperture weatherstrip(s)
from around the scuff plate location.
20 Remove the B-pillar trim, as applicable.
21 Remove the lower seat belt anchor bolt on
five-door models, and detach the anchor from
its location.
22 On three-door models, remove the bolt
securing the forward end of the seat belt slide
bar, then manoeuvre the slide bar to free it
from its rear location.
23 Remove the plastic screws securing the
sill scuff plate, then slip the seat belt through
its slot on five-door models, and remove the
sill scuff plate from the vehicle (see
illustration) . Should the soft plastic screws
round off during attempts to remove them,
force an electrician’s thin screwdriver into the
body of the screw and try again, fitting a new
screw upon reassembly.
Refitting
24 Refitting is a reversal of the removal
procedure, tightening the seat belt anchor
bolts to the specified torque.
Rear quarter trim panel
Removal
25 Detach the door aperture weatherstrip
from around the trim location.
26 Remove the rear seat cushion, as
described in Section 40.
27 Remove the screw from the upper rear
corner of the trim panel.
28 Remove the plastic stud from the lower
rear corner of the trim panel.
29 Detach the seat belt slide bar by removing
the bolt from its forward end then
manoeuvring it to free it from its rear location
(see illustration) . Remove the seat belt from
the slide bar.
30 Release the trim clips from the front and
top edges of the panel using a trim clip tool.
This may be achieved by carefully inserting
two thin flat-bladed screwdrivers between the
panel and the body - one each side of the clip
being released, and applying gentle leverage,
if a trim clip tool is not available.
Bodywork and fittings 11•19
42.11 C-pillar trim fixings
A Screw locations
B Parcel shelf support/rear loudspeaker housing location42.1 A-pillar trim retaining screw (A),
heated windscreen live wire (B) and heated windscreen earth wire (C)
42.29 Seat belt lower slide bar anchorarrangement (three-door models)
A Bush location B Anchor bolt42.23 B-pillar trim being removed to
expose seat belt removal/refitting slot in sill scuff plate (arrowed)
11
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